Drywall repair fastener and method of using the same

ABSTRACT

A drywall repair hardware and method of using the same. The drywall repair hardware includes a flat plate with a joint arm extending from an outer surface of the flat plate around a median portion thereof. At least one prong protrudes from an end of the joint arm generally parallel to the flat plate. The at least on prong is engaged to embed into a side edge of the drywall surrounding the hole to be repaired. An adhesive joins the repair hardware to the back interior surface of the drywall to be repaired. Once the repair hardware is adhered to the wall, the adhesive is applied to the opposite ends of the plate and the patch is inserted to repair the hole.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority of U.S. provisional application No. 62/567,859, filed Oct. 4, 2017, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to drywall construction, and more particularly to repair or installation of drywall to an opening in the drywall surface.

Patching of holes in drywall can be a difficult task, particularly where such holes are typically arise, which is in the spaces between the underlying stud support members. With other drywall repair devices in the art screws are required to drill to fasten them to a support structure. Similarly, many require the repair to tape over visible clips, making it more difficult to apply joint compound to achieve a smooth finish.

As can be seen, there is a need for an apparatus and method for an improved drywall repair hardware and method of using the same.

SUMMARY OF THE INVENTION

In one aspect of the present invention a drywall repair fastener, for mounting a drywall patch in an opening of a drywall panel, is disclosed. The drywall repair fastener includes a substantially flat plate having an inner surface and an outer surface. A joint arm extends substantially orthogonal to the outer surface of the plate. At least one prong extends generally orthogonal from the joint arm, the prong having a drywall penetrating tip.

An infiltration surface may be defined in the outer surface of the plate, the infiltration surface providing for reception and adherence with an adhesive. The infiltration surface may include a plurality of holes extending through the plate.

In preferred embodiments, the joint arm protrudes from the plate such that the least one prong is spaced apart from the plate by a distance that is less than that of a thickness of the drywall panel. More preferably, the at least one prong is positioned at a median thickness of the drywall. The joint arm may extend from a median portion of the outer surface of the plate. In some embodiments, the flat plate is rectangular.

In other aspects of the invention, a method of repairing a hole in a drywall panel, is disclosed. The method includes applying an adhesive to an interior surface of the drywall panel at one or more selected locations around the periphery of the opening. A drywall repair fastener is then applied to the drywall at the one or more selected locations. The drywall repair fastener having a substantially flat plate, a joint arm that extends from an outer surface of the plate, and at least one prong that extends generally orthogonal from the joint arm. The at least one prong is penetrated into a side edge of the drywall surrounding the hole. A first end of the plate is them pressed for engagement of the outer surface of the plate with the adhesive.

In other embodiments, a subsequent drywall repair fastener is applied to another of the one or more selected locations carrying the adhesive. The method further includes applying an adhesive to a second end of the plate. When installed, an adhesive is applied to a second end of the subsequent drywall repair fastener. A patch is then inserted into the opening so that an interior side of the patch engages with the adhesive on the second end of the plate.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of the drywall repair hardware shown in use.

FIG. 2 is a rear elevation view of the drywall repair hardware shown in use.

FIG. 3 is a perspective view of the drywall repair fastener.

FIG. 4 is a cross-sectional view of a drywall repair fastener applied to a repair taken on line 4-4 of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, embodiments of the present invention provide an improved drywall repair hardware and method that facilitates patching of holes or openings in drywall. The present invention is particularly well suited for use where there are no underlying studs to support at least a portion of the drywall patch.

Aspects of the present invention are shown in reference to FIGS. 1 and 2 in which a plurality of drywall repair fasteners 10 are disposed in a spaced apart relationship to mount a section of drywall, or patch 14 in an exterior surface 12 of drywall wall panel. The drywall repair fasteners 10 have a back plate 18 that is oriented to rest against an interior surface of the wall 12 b and patch 14.

As seen in reference to FIG. 3, a detail view of a drywall repair fastener 10 according to the present invention is shown. In the embodiment shown, the drywall repair fastener 10 includes a substantially flat plate 18 having in inner surface and an outer surface. As will be appreciated from the benefit of applicant's disclosure, only the outer, wall contacting surface is substantially flat. An infiltration surface is defined in the outer surface for reception and adherence with an adhesive, the infiltration surface may be a plurality of grooves, ridges, ribs, or other texture in the flat surface. The fastener 10 may be formed from a plastic, nylon, or metal or other suitable material, preferably ABS plastics.

In the non-limiting embodiment shown, the infiltration surface includes a plurality of holes 16 extending through a front surface and a back surface of the plate 18. The plate 18 is generally rectangular around its peripheral aspects, however, as will be appreciated from applicant's disclosure, almost any shape around the peripheral aspects of the plate may be suitable to practice the invention. The holes 18 are disposed in a spaced apart relationship and are dimensioned so that an adhesive 24 may ooze through the holes 16 to retain the drywall repair fastener 10 to the interior surface of the drywall 12 b and the patch 14.

A joint arm 20 extends substantially orthogonal to an outer face of the plate 18. At least one prong 22 extends generally orthogonal from the joint arm 20, in order to engage with, and preferably embed or penetrate into a side edge of one of the drywall 12 or the drywall patch 14. The joint arm 20 protrudes from the plate 18 such that the least one prong 22 is spaced apart from the plate 18 by a distance that is less than that of the thickness of the drywall panel 12 and patch 14 to be repaired. Preferably, the at least one prong 22 is positioned at a median portion of the side edge of the drywall.

As best seen in reference to FIG. 4, the joint arm 20 will have a thickness to maintain a desired spacing between the drywall panel 12 and the patch 14 for the application of joint compound.

In use, a suitable adhesive 24 may be applied to the interior surface of the wall 12 b and the drywall repair fastener 10 is placed so that the at least one prong 22 is engaged with and preferably penetrates a side edge of the drywall 12 surrounding the hole. The outer face of the drywall repair fastener 10 may then be pressed into the adhesive 24. One or more additional drywall repair fasteners 10 may then be applied in like manner about the periphery of the hole to be repaired. Depending upon the adhesive 24, a clamp may be used to hold the drywall repair fastener 10 in a close engagement with the drywall 12 as the adhesive 24 cures.

Once the plurality of drywall repair fasteners 10 have emplaced within the hole, the drywall patch 14 may be installed. The adhesive 24 may be applied to the remaining outer surface of the plate 18 or to the corresponding interior surfaces of the patch 14 for each of the plurality of drywall repair fasteners 10. Once the adhesive 24 has been applied, the patch 14 may be inserted into position within the hole. The patch 14 may be held or braced in position while the adhesive 24 cures. Once the adhesive 24 has cured, the repaired hole may be finished by application of a tape and joint compound and sanded.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A drywall repair fastener, for mounting a drywall patch in an opening of a drywall panel, comprising: a substantially flat plate having an inner surface and an outer surface; a joint arm extends substantially orthogonal to the outer surface of the plate; and at least one prong extends generally orthogonal from the joint arm, the prong having a drywall penetrating tip.
 2. The drywall repair fastener of claim 1, further comprising: an infiltration surface defined in the outer surface of the plate, the infiltration surface providing for reception and adherence with an adhesive.
 3. The drywall repair fastener of claim 2, wherein the infiltration surface comprises a plurality of holes extending through the plate.
 4. The drywall repair fastener of claim 1, wherein the joint arm protrudes from the plate such that the least one prong is spaced apart from the plate by a distance that is less than that of a thickness of the drywall panel.
 5. The drywall repair fastener of claim 4, wherein the at least one prong is positioned at a median thickness of the drywall.
 6. The drywall repair fastener of claim 1, wherein the joint are extends from a median portion of the outer surface of the plate.
 7. The drywall repair fastener of claim 1, wherein the flat plate is rectangular.
 8. A method of repairing a hole in a drywall panel, comprising: applying an adhesive to an interior surface of the drywall panel at one or more selected locations around the periphery of the opening; applying a drywall repair fastener to the drywall at the one or more selected locations, the drywall repair fastener having a substantially flat plate, a joint arm that extends from an outer surface of the plate, and at least one prong that extends generally orthogonal from the joint arm, penetrating the at least one prong into a side edge of the drywall surrounding the hole; and pressing a first end of the plate for engagement of the outer surface of the plate with the adhesive.
 9. The method of claim 8, further comprising: applying a subsequent drywall repair fastener to another of the one or more selected locations carrying the adhesive.
 10. The method of claim 8, further comprising: applying an adhesive to a second end of the plate.
 11. The method of claim 10, further comprising: applying an adhesive to a second end of the subsequent drywall repair fastener.
 12. The method of claim 11, further comprising: inserting a patch into the opening so that an interior side of the patch engages with the adhesive on the second end of the plate.
 13. A drywall repair fastener, for mounting a drywall patch in an opening of a drywall panel, comprising: a plate having an inner surface and a flat outer surface; a joint arm extending substantially orthogonal to the outer surface of the plate; and at least one prong protruding orthogonal from the joint arm, the prong having a drywall penetrating tip.
 14. The drywall repair fastener of claim 13, further comprising: an infiltration surface defined in the outer surface of the plate, the infiltration surface providing for reception and adherence with an adhesive.
 15. The drywall repair fastener of claim 14, wherein the infiltration surface comprises a plurality of holes extending through the plate.
 16. The drywall repair fastener of claim 13, wherein the joint arm protrudes from the plate such that the least one prong is spaced apart from the plate by a distance that is less than that of a thickness of the drywall panel.
 17. The drywall repair fastener of claim 16, wherein the at least one prong is positioned at a median thickness of the drywall.
 18. The drywall repair fastener of claim 13, wherein the joint are extends from a median portion of the outer surface of the plate. 